Stator Wedge Member with Integral Coupling Portion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional stators for rotary electric machines face challenges in inserting and securely holding wedge members into slots without bending or folding, which complicates the production process and requires individual insertion of each wedge member.
Innovation Solution
The integration of a coupling portion with the wedge members, made of synthetic resin, enhances their strength and allows for simultaneous insertion into multiple slots using a pressing force, with optional continuous coupling portions forming an annular wall for enhanced insulation and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wedge members are individually inserted into slots one by one, then insulation between adjacent magnetic pole portions is ensured, but the production process becomes complex and time-consuming
Solution Approach 1:
Multiple wedge members are integrated into a single integral insulating member, allowing them to be inserted into multiple slots simultaneously as one unit rather than individually. This merging approach maintains the insulation function across all slots while dramatically improving production efficiency by reducing the number of insertion operations from multiple individual insertions to a single collective insertion.
2Ease of operation
If conventional wedge members are folded to fit into slots, then insertion is possible, but the wedge members may be bent or folded during insertion causing production issues
Solution Approach 1:
The insulating member is designed with a three-dimensional structure that includes protrusions extending in the radial direction to engage with grooves in the slots. This dimensional approach allows the member to be inserted without folding or bending, as the protrusions guide the insertion and lock into place, maintaining structural integrity while achieving secure fit.
Solution Approach 2:
The insulating member is pre-formed with specific geometric features including protrusions and grooves that are designed to match the slot configurations. This preliminary shaping ensures that the member can be directly inserted without requiring folding or bending during the insertion process, preserving manufacturing precision.
3Reliability
If wedge members are made from folded synthetic-resin sheets, then insulation is provided, but the structure lacks sufficient strength and may bend or fold
Solution Approach 1:
The insulating member is formed as an integral structure from synthetic resin material that combines insulating properties with structural strength. The monolithic construction eliminates the weakness of folded sheets while maintaining the electrical insulation function, providing both reliability and strength in a single component.
Data Source
AI summary
A stator for a rotary electric machine with wedge members insertable into slots without being bent or folded is provided. A coupling portion is integrally formed at a non-inserted end portion, which is not inserted into a slot, of a wedge member, the coupling portion extending across an end of a partition wall portion and an end of a block portion. The wedge member and the coupling portion are formed of a synthetic resin material. Two or more coupling portions of two or more adjacently disposed wedge members are integrally formed as a continuous coupling portion.